Onan Elite E125H, Elite E140H Owner's Manual

,98<7 37:87;

,&').$ ,&(%.

0756843 56 2#1#, +('9$%)+

)9+)

Emissions Supplement:

900-1

021

Date:

07-2000

Insert

with-

Manual Number & Date:

See

Table

1

Models:

See

Table

1

965-0176
981-0153

Purpose:

This supplement for the Operator's

Manuals specified in Table

1

clarifies how com­pliance with engine emissions regulations, includ­ing

U.

S.

EPA Phase 2 and California Air Re­sources Board regulations for Model Year 2000
onwards, is presented on genset and engine
nameplates (Figures

1

and 2). This sheet is to be
bound in the genset or engine manual behind the
front cover and in front of earlier Supplements, if
any.

7/97

1

BGE / NHE

7/97

I

KV

TABLE

1.

MANUALS AFFECTED

BY

SUPPLEMENT

Manual

No.

I

Date

1

Genset Models

965-0138

I

5/97

I

BGM / NHM

I

965-0175

I

7/97

1

BGD I NHD

I

I

981-0158

I

6/99

I

KVC

I

981-0159

I

5/00

I

KY

981-0160

I

7/99

I

MKY

I

983-0101

1

5/00

I

HGJAAIHGJABIHGJAC

1

For engines of less than 225 cc displacement,
Category C

=

125 hrs, B = 250 hrs, A

=

500

hrs.

For engines

of

225 cc and greater displacement,

Category C

=

250 hrs, B

=

500

hrs, A = 1000

hrs.

r

IMPORTANT ENGINE INFORMATION

CURRMlNS

POWER

GENERATlOM

1400

73rd

Avo. NE

Minneapolis,

MN

55432

Made

in

USA

Modd

No:

PH

kVA:

kW:

pf:

RPM

Ha

Bat:

wring

DiagME

InsuIatbn

-

NEMA

Qan

F

Ambiant

40°C

flhe engine family designation, engine displacement, statement

of

compliance with the applicable

EPA

and/or California emissions
regulations, including the compliance period or category; appear in
this block on the actual nameplate on the genset.]

Manual

No. I Date

I

Engine Models

965-0163

I

10/95 I Miller P216 / P218 / P220 I P224

FIGURE

I.

TYPICAL GENSET NAMEPLATE

965-0174 I 10/97

I

E124V Floorcare

965-0178

I

7/97

I

E125V/ E140V

I

965-0179 I 7/97

I

E125H I E140H

I

965-0180

I

7/97

I

P218V I P220V

965-0182B

1

-

I

P216 / P218 / P220 I P224

I

965-0183

I

-

I

P248V Floorcare

I

Nameplate Information:

See the Operator's

Manual for the location of the actual nameplate on

the genset or engine. Figures

1

and 2 illustrate

where the information regarding compliance with

U.

S.

EPA and California Air Resources Board
regulations on the nameplate. The appropriate
figure in this supplement supercedes the nameplate
illustration in Figure 1 in the genset or engine
manual in which the supplement is bound.

Federal Emissions Compliance Period:

The

Federal Emissions Compliance Period referred

to

on the nameplate indicates the number of operating
hours for which the engine has been shown to meet
Federal emissions requirements.

f

IMPQRTAMT

ENGINE

INFORMATION

)

ONAN CORPORATION

1400

73rd

Ave.

NE

Minneapolis,

MN

55432

Made in Canada

Engine

Model:

SIN:

rhe

engine family designation, engine displace-

ment, statement of compliance with the applicable

EPA

and / or California emissions regulations, in-

cluding

the

compliance period

or

category; appear in

this

block on the actual nameplate on the engine.]

FIGURE

2.

TYPICAL ENGINE NAMEPLATE

Page

1

of

1

Safety Precautions

Before operating the engine, read this manual and become

familiar with it and the equipment. Safe and efficient
operation can be achieved only if the equipment is
properly operated and maintained.

The following symbols, found throughout this manual, alert you
to potentially dangerous conditions to the operator, service per-
sonnel, or the equipment.

This symbol warns of immediate hazards

which will result in severe personal injury or death.

6*20/0-

practice which can result in severe personal injury or
death.

+*54/10

practice which can result in personal injury or product or
property damage.

Fuels, electrical equipment, batteries, exhaust gases and
moving parts present potential hazards that can result in severe
personal injury. Ta ke care in following these recommended
procedures. All local, state and federal codes should be
consulted and complied with.

6*20/0-

use in any type of aircraft. Use of this engine in aircraft can
result in engine failure and cause severe personal injury or
death.

GENERAL

This symbol refers to a hazard or unsafe

This symbol refers to a hazard or unsafe

This engine is not designed or intended for

• Provide appropriate fire extinguishers and install them in

convenient locations. Use an extinguisher rated ABC by
NFPA.

• Make sure that all fasteners on the engine are secure and

accurately torqued. Keep guards in position over fans,
driving belts, etc.

• If it is necessary to make adjustments while the engine is

running, use extreme caution when close to hot exhausts,
moving parts, etc.

• Used engine oils have been identified by some state and

federal agencies as causing cancer or reproductive
toxicity. When checking or changing engine oil, take care
not to ingest, breathe the fumes, or contact used oil.

• Do not work on this equipment when mentally or

physically fatigued, or after consuming any alcohol or
drug that makes the operation of equipment unsafe.

BATTERIES

• Before starting work on the engine, disconnect batteries

to prevent inadvertent starting of the engine. Disconnect
negative (–) cable first.

• DO NOT SMOKE while servicing batteries. Lead acid bat-

teries give off a highly explosive hydrogen gas which can
be ignited by flame, electrical arcing or by smoking.

• Verify battery polarity before connecting battery cables.

Connect negative (–) cable last.

PROTECT AGAINST MOVING PARTS

• Do not wear loose clothing in the vicinity of moving parts,

such as PTO shafts, flywheels, blowers, couplings, fans,
belts, etc.

• Keep your hands away from moving parts.

FUEL SYSTEM

• DO NOT fill fuel tanks while engine is running.

• DO NOT smoke or use an open flame in the vicinity of the

engine or fuel tank. Internal combustion engine fuels are
highly flammable.

• Fuel line must be of steel piping, adequately secured, and

free from leaks. Piping at the engine should be approved
flexible line. Do not use copper piping for flexible lines as

copper will work harden and become brittle enough to
break.

• Be sure all fuel supplies have a positive shutoff valve.

• Benzene and lead, found in some gasoline, have been

identified by some state and federal agencies as causing
cancer or reproductive toxicity. When checking, draining

or adding gasoline, take care not to ingest, breathe the
fumes, or contact gasoline.

EXHAUST SYSTEM

• Exhaust products of any internal combustion engine are

toxic and can cause injury, or death if inhaled. When
operating the engine in a confined area, make sure the
ventilation system is operating properly.

• DO NOT use exhaust gases to heat a compartment.

• Make sure that your exhaust system is free of leaks. Make

sure that exhaust manifolds are secure and are not
warped by bolts unevenly torqued.

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, a poisonous gas that
can cause unconsciousness and death. It is an odorless and
colorless gas formed during combustion of hydrocarbon fuels.
Symptoms of carbon monoxide poisoning are:

• Dizziness • Vomiting

• Headache • Muscular Twitching

• Weakness and Sleepiness • Throbbing in Temples

If you experience any of these symptoms, get out into fresh air
immediately, shut down the unit and do not use it until it has

been inspected.
The best protection against carbon monoxide inhalation is

proper installation and regular, frequent inspections of the
complete exhaust system. If you notice a change in the sound
or appearance of exhaust system, shut the unit down immedi­ately and have it inspected and repaired at once by a competent
mechanic.

KEEP THE UNIT AND SURROUNDING AREA CLEAN

• Make sure that oily rags are not left on or near the engine.

• Remove all unnecessary grease and oil from the unit.

Accumulated grease and oil can cause overheating and
subsequent engine damage and present a potential fire
hazard.

E-8

Table of Contents

WARNING

personal injury and equipment damage. Service personnel must be qualified
to perform electrical and/or mechanical service.

Title Page

Safety PrecautionsInside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Periodic Maintenance8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important Information for California Engine Users 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Improper service or replacement of parts can result in severe

##

The engine exhaust from this product

contains chemicals known to the State

of California to cause cancer, birth
defects or other reproductive harm.

i

Introduction

ABOUT THIS MANUAL

This manual covers the operation and maintenance
of the horizontal-shaft Elite Series of engines. Each
operator of the power equipment should study this
engine manual carefully and observe all of its
instructions and precautions. Proper use and peri­odic maintenance are responsibilities of the opera-
tor(s) and are essential for top performance.

MODEL IDENTIFICATION

Whenever contacting an Onan dealer or distributor
for information, parts or service, always provide the
model number and the serial number marked on the
nameplate of the engine. Figure 1 illustrates a typi-

cal engine nameplate and Figure 3 the location of
the nameplate on the engine.

Genuine Onan replacement parts obtained from an
Onan dealer or distributor are recommended.

THIS ENGINE MEETS U.S. EPA PH1 AND 1995–1998

CALIFORNIA EMISSIONS REGULATIONS FOR ULGE ENGINES

FIGURE 1. TYPICAL ENGINE NAMEPLATE

1

AIR FILTER

HOUSING

FUEL SHUTOFF

VALVE

(if so equipped)

CHOKE AND THROTTLE CABLE CLAMPS

(may be equipped with levers instead)

See ADJUSTMENTS

ON-OFF SWITCH

(if so equipped)

FUEL TANK

(if so equipped)

OIL FILTER

FIGURE 2. FRONT VIEW OF TYPICAL ENGINE

RECOIL STARTER

(if so equipped)

AIR INLET

SCREEN

(not illustrated)

2

SPARK PLUG

LONG OIL FILL

TUBE

(if so equipped)

BATTERY CHARGING

VOLTAGE REGULATOR

(if so equipped)

STATIONARY AIR

INLET SCREEN

(if so equipped)

ROTATING AIR

INLET SCREEN

(if so equipped)

MUFFLER

(if so equipped)

ELECTRIC STARTER

(If so equipped)

SHORT OIL FILL

TUBE

(If so equipped)

OIL DRAIN

AIR FILTER

HOUSING

CRANKSHAFT

GOVERNOR SHAFT

AND ARM

(see Adjustments)

FIGURE 3. RIGHT AND LEFT SIDES OF TYPICAL ENGINE

3

FUEL FILTER

ENGINE

NAMEPLATE

OIL DRAIN

FUEL RECOMMENDATIONS

Use clean, fresh unleaded gasoline having a mini­mum octane rating (Anti-Knock Index) of 87.

During some times of the year only mandated “oxy-
genated” gasolines may be available. These are
acceptable for use, but not preferable. Leaded gas­oline may be used but will result in the extra mainte­nance required for removing combustion chamber
and spark plug deposits. Do not use gasoline or
gasoline additives (de-icers) containing methanol

because methanol can be corrosive to fuel system
components.

+*54/10

ditives containing methanol because methanol
can be corrosive to fuel system components.

Avoid using highly leaded gasolines and lead
additives because of the extra engine mainte-
nance that will be required.

6*20/0-

can cause severe personal injury or death. Do
not smoke if you smell gasoline or are near fuel

tanks or gasoline-burning equipment or are in
an area sharing ventilation with such equip-
ment. Keep flames, sparks, pilot lights, electri­cal arcs and arc-producing equipment and all
other sources of ignition well away.

Do not use gasoline or gasoline ad-

Gasoline is highly flammable and

TABLE 1. OIL VISCOSITY VS. TEMPERATURE

EXPECTED AMBIENT

TEMPERATURES

32° F (0 ° C) and higher 30

10 ° F to 100° F (–12 ° C to 38 ° C)

0 ° F to 80 ° F (–18° C to 27° C)

–20° F to 50 ° F (–28 ° C to 10 ° C) 5W-30

SAE

VISCOSITY

GRADE

15W-40

(OnaMax)

10W-30
10W-40

STARTING BATTERIES

An engine equipped with an electric starter requires
a 12 volt starting battery. Prompt starting requires
sufficient battery capacity and battery cable size.
Neither cranking performance nor starter service
life will be satisfactory with an undersized battery.

Regular, monthly maintenance of batteries may be

required. See Periodic Maintenance and any
instructions available from the equipment or battery
manufacturer. It should be noted that as long as the
equipment is operated regularly, the automatic bat-

tery recharging system on the engine should be
able to maintain battery charge. See OUT-OF-
SERVICE PROTECTION under Operation regard-

ing battery care during storage for prolonged peri­ods.

EXHAUST SYSTEM

ENGINE OIL RECOMMENDATIONS

Use premium quality motor oil. Look for the API
(American Petroleum Institute) classification and

use Class SG or SH oil (also SG/CD, SG/CE, SH/
CD or SH/CE). Also look for the SAE (Society of Au-
tomotive Engineers) viscosity grade. Referring to
Table 1, choose the viscosity grade appropriate for

the ambient temperatures expected during the peri-
od of time until the next scheduled oil change.

Single-grade SAE 30 oil is preferable when temper-
atures are consistently above freezing. Multigrade
oils are better when wide temperature variations
are expected.

EXHAUST GAS IS DEADLY! Mobile engine-pow-
ered equipment must never be operated inside
buildings or other enclosed spaces without ample
fresh air ventilation.

Stationary engine-powered equipment installed in-

side buildings or other enclosed spaces must be
equipped with a leak-free exhaust system that car-

ries all exhaust gases to the outside, well away from
all windows, doors, vents and other openings into
the building or enclosure.

It is the responsibility of the equipment operator(s)

to check for exhaust leaks on a daily basis and to
have all leaks repaired before continuing to operate
the equipment.

4

Operation

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon monoxide is poi-
sonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning in-
clude:

• Dizziness • Throbbing in Temples

• Nausea • Muscular Twitching

• Headache • Vomiting

• Weakness and Sleepiness • Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH
AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the engine and do not
operate it until it has been inspected and repaired.

Make certain the exhaust system is properly installed. Inspect it every time the engine is started
and after every eight hours of continuous operation.

PRE-START CHECKS

Before the first start of the day and after every eight
hours of operation perform the maintenance
instructed in DAILY (8 HOUR) MAINTENANCE un-
der Periodic Maintenance . Keep a log of mainte­nance and the hours run and perform any mainte­nance that may be due. Also, if the equipment has
been in storage, return the engine to service as
instructed under RETURNING THE ENGINE TO

SERVICE in this section.
Always follow the equipment manufacturer’s oper-

ating instructions and observe all precautions when
operating power equipment.

6*20/0-

personal injury or death. Hot exhaust parts can
cause severe burns. Stay clear of hot or moving

parts. Make sure all protective shields and
guards are secure in place before starting up
the equipment.

Moving parts can cause severe

STARTING

3.Release the clutch if the engine is so equipped.

4. Pull the choke knob out to its full-choke position.

Note: Try starting without the choke in warm
weather or when the engine is warm.

5. Push the throttle knob or lever to the middle of
its speed range.

6.If so equipped, turn the ignition key switch to its
run position.

7.Pull the recoil starter handle to crank the en-
gine. If the engine is equipped with an electric
starter, push the start switch to its start position

and hold it there until the engine starts. Do not
crank for more than 30 seconds at a time and
wait at least one minute between tries when
cranking with an electric starter. See Trouble -
shooting if the engine does not start after sever-
al tries.

1. Check the oil level if this is the first start of the
day and add oil as necessary.

+*54/10

will cause severe engine damage. Always
keep the engine oil level between the Full
and Add marks on the dipstick.

2.Fill the fuel tank, if necessary, and open any fuel
line shutoff valve.

Starting the engine without oil

5

8. After the engine starts, keep your hand on the
choke knob and slowly push it in to the full-open
choke position, pulling back if necessary to

keep the engine running smoothly. The colder
the weather the longer it will take the engine to
start running smoothly with the choke fully

open. Do not operate the equipment until the
engine has warmed up sufficiently to run
smoothly with the choke fully open.

ENGINE BREAK-IN

OPERATION IN HOT WEATHER

Engine break-in as a result of proper care during the
first hours of operation of a new or rebuilt engine re­sults in the ideal fitting of all internal moving metal
parts, which is essential for top engine perfor-
mance. For controlled engine break-in:

1. Operate the equipment as it is intended to be
operated. However, for the first 1-1/2 hours, if
possible, operate the equipment at about half

the available engine power, occasionally oper­ating at full engine power for brief periods.
Also, if possible, avoid prolonged low-speed,

low-power operation during engine break-in.

2.Proper engine oil is especially critical during

break-in because of the higher engine temper-
atures that can be expected. See REC­OMMENDED ENGINE OIL in Introduction.
Change the oil if it is not appropriate for the am-
bient temperatures during the break-in period.
See Ta ble 1.

3.Check the oil level twice a day or after every 4
hours of operation during the first 24 hours of
operation.

4. Change the oil and oil filter after the first 24
hours of operation and have the valves read­justed by a qualified mechanic.

OPERATION IN DUSTY CONDITIONS

1. Keep the engine cooling fins and flywheel air
inlet screen clean.

2.Perform air cleaner maintenance more often
than normal—as required. See Table 2.

3.Change the engine oil and oil filter more often
than normal. See Table 2.

Pay particular attention to the following items when
operating the engine in temperatures above 100° F
(38 °C):

1. Keep the flywheel air inlet screen and cylinder

cooling fins clean. See to it that nothing ob-
structs air flow to and from the engine.

2.Check the oil level more frequently.

3.Change the oil and oil filter more often than nor-

mal. See Table 2.

4. Make sure the engine oil viscosity is appropri-

ate for the ambient temperatures and change
the oil if necessary. See Table 1.

OPERATION IN COLD WEATHER

Pay particular attention to the following items when
operating the engine in temperatures below freez­ing:

1. Make sure the engine oil viscosity is appropri-

ate for the ambient temperatures and change
the oil if necessary. See Table 1. If the tempera-
ture drops before you have the chance to
change the oil, warm up the engine by moving
the equipment into a heated space before at­tempting to start the engine or change oil.

6*20/0-

Never operate mobile engine-powered
equipment indoors without ample fresh air
ventilation.

2.Use fresh fuel and fill the fuel tank after each
day’s use to reduce problems with moisture

condensation.

3.Keep the battery in a well-charged condition.

4. After each use push the equipment throttle
knob or lever to the middle of its speed range so

that if ice forms on the linkage during storage it
will be easier to start the engine.

EXHAUST GAS IS DEADLY!

6

OUT-OF-SERVICE PROTECTION

Protect an engine that will be out of service for more
than 30 days as follows:

1. Run the engine until it reaches normal operat-
ing temperature, shut off the fuel supply and let
the engine run until it stops. Also, if the equip-
ment will not be operated for more than 120
days, add a fuel preservative (OnaFreshTM) to
the equipment fuel tank. Follow the instructions
on the container label. Unless a preservative
(stabilizer) is added, the gasoline will deterio-

rate causing fuel system corrosion, gum forma-
tion and varnish-like deposits which can lead to
hard starting and rough operation.

6*20/0-

lizers) are toxic. Follow the instructions on
the container label. Avoid skin contact.

Wash your hands with soap and water after
dispensing the fluid.

2.Drain the oil from the engine while it is still
warm. Refill with fresh oil and attach a tag stat-
ing the viscosity of the oil used.

3.Remove the spark plug and squirt 1 ounce

(2 tablespoons or 28 grams) of rust inhibitor or
SAE 30 oil into the cylinder. Crank the engine

over a few times and reinstall the spark plug.

4. Perform air cleaner maintenance as instructed
in Periodic Maintenance .

5. Clean the governor linkage and wrap it with a
clean cloth for protection.

Gasoline preservatives (stabi-

6.Plug the exhaust outlet to prevent moisture,
dirt, bugs, etc. from entering.

7.Provide a suitable cover for the entire unit.

8. If so equipped, disconnect the battery (nega-
tive [ – ] cable first) and follow the battery or
equipment manufacturer’s storage instruc­tions.

RETURNING THE ENGINE TO SERVICE

1. Remove the cover and all protective wrapping
and the plug from the exhaust outlet.

2.Check the tag on the oil base. Change the oil if
the viscosity is not appropriate for the expected
ambient temperatures. See Table 1.

3.Check the fuel filter and fuel lines to make sure
they are secure and have no cracks or leaks.

4. Check to see that the choke, throttle and gover-
nor linkages move freely.

5. If so equipped, clean and check the battery ac-

cording to the battery or equipment manufac-
turer’s instructions and connect the battery
cables (positive [ + ] cable first).

6.Start the engine. The initial startup may be slow

and there may be smoke and rough operation
for a few minutes until the oil in the cylinder

burns off. If the engine does not start, clean or
replace the spark plug as it may have been

fouled by the oil added to the cylinder when the
equipment was stored.

OnaFresh is a trademark of the Onan Corporation.

7

Periodic Maintenance

Periodic maintenance is essential for top engine

sis for supporting warranty claims.
performance. Use Ta ble 2 as a guide for normal pe-
riodic maintenance. Under hot or dusty operating

conditions some maintenance operations should
be performed more frequently, as indicated by the

footnotes in the table. Keep a log of maintenance
performed and the hours run. Recording mainte-

Maintenance, replacement or repair of emission

control devices and systems may be performed by

any engine repair establishment or individual. How-

ever, warranty work must be completed by an

authorized Onan dealer or distributor.
nance will help you keep it regular and provide a ba-

TABLE 2. PERIODIC ENGINE MAINTENANCE SCHEDULE

MAINTENANCE FREQUENCY

MAINTENANCE OPERATION

Inspect Engine X

Check Oil Level X

Clean Air Cleaner Foam Wrapper X

Clean Cylinder Cooling Fins X

Check Starting Battery (if so equipped) X

Every Day
or Every 8

Hours

1

Every 50

Hours

3

3

Every

Month

5

Every 100

Hours

Every

200 Hours

Every 400

Hours

Change Engine Oil and Oil Filter X

Replace Fuel Filter (if so equipped) X

Replace Air Cleaner Element X

Adjust Engine Valve Clearance X

Inspect, Clean and Re-gap Spark Plug X

Replace Spark Plug X

1Check for oil, fuel and exhaust leaks, loose parts and unusual noises and vibrations.
2Perform after the first 24 hours of operation as a part of engine break-in.
3Perform more often when operating in dusty conditions.

4Perform more often when operating in hot conditions.
5See instructions for battery care provided by the equipment or battery manufacturer.

6Must be performed by a qualified mechanic (equipment or Onan dealer).

2,3,4

3

2,6

8

DAILY (8 HOUR) MAINTENANCE

The operator should check the following before the
first start of the day and after every eight hours of
operation:

1. Inspect fuel lines and fittings for leaks. Repair
leaks immediately.

2.Look and listen for exhaust system leaks while
the engine is running. Look for cracks and se-
vere rusting in the muffler and tailpipe. Have all

leaks repaired before continuing to operate the
equipment.

6*20/0-

severe burns. Allow the engine time to cool
before servicing the exhaust system.

3.Check the engine for dirt and debris and clean
the flywheel air inlet screen and cylinder cool-
ing fins as necessary.

+*54/10

screen or dirty cooling fins can cause over­heating and engine damage. Keep the cool-
ing fins and air inlet screen clean.

Hot exhaust parts can cause

A clogged flywheel air inlet

tube until the cap seats and then withdraw it to
check the oil level.

If the oil level is low, add API Class SG or SH oil

(also SG/CD, SG/CE, SH/CD or SH/CE) hav­ing an SAE viscosity grade appropriate for the
expected temperatures, as indicated by

Table 1.
DO NOT FILL TO A LEVEL ABOVE THE FULL

MARK ON THE DIPSTICK. Drain the excess
oil if too much has been added.

+*54/10

Too much oil can cause high oil
consumption, high operating temperatures
and oil foaming. Too little oil can cause se-

vere engine damage. Keep the oil level be-
tween the Full and Add marks on the dip-
stick.

Reinstall the dipstick and cap after checking or
adding oil, making sure the cap is properly
seated. On engines with long oil fill tubes, se-
cure the cap by pushing it down and turning it
clockwise.

4. Check the engine oil level. The equipment
must be parked on a level surface and the en-
gine stopped. To get an accurate reading, wait

a minute or so to allow the oil to settle in the
crankcase if the engine has been running.

6*20/0-

Crankcase pressure can blow

hot engine oil out the fill tube causing se-

vere burns. Always stop the engine before
removing the oil fill cap.

If the engine is equipped with the long oil fill
tube (Figure 3), turn the oil fill cap (Figure 4)

counterclockwise and then lift up. If the engine
is equipped with the short oil fill tube, pull the
dipstick up to remove it from the fill tube. Wipe

the dip stick clean, push it back into the oil fill

TWIST-LOCK

CAP USED ON

.19%&&$

FIGURE 4. OIL FILL CAP AND DIPSTICK

LONG DIP TUBE

FULL MARK

ADD MARK

9

ENGINE OIL AND FILTER CHANGE

5. Thoroughly wipe off the filter mounting surface.

6*20/0-

State and federal agencies have de-

termined that contact with used engine oil can

cause cancer or reproductive toxicity. Take
care to limit skin contact and breathing of va-
pors as much as possible. Use rubber gloves
and wash exposed skin.

Refer to Ta ble 2 for scheduled oil change and filter
replacement. See Figures 2 and 3 (Pages 2

and 3) for oil filter and oil drain locations.

1. Run the engine until it is warm. Stop the engine
and disconnect the spark plug and, if so
equipped, the battery (negative [–] cable).

6*20/0-

Accidental starting of the en-
gine can result in severe personal injury or
death. Always disconnect the spark plug

and the battery (negative [–] cable) before
changing oil.

2.Remove the oil fill cap.

6*20/0-

Crankcase pressure can blow
hot engine oil out the fill opening causing
severe burns. Always stop the genset be-
fore removing the oil fill cap.

3.Place a pan under the oil drain opening and re-
move the oil drain plug. Reinstall the plug se­curely after the oil has drained completely.

4. Spin off the oil filter canister, drain the oil and
discard the filter according to local regulations.

6.Make sure the gasket is in place on the filter
canister and apply a thin film of oil to the gasket.

7.Spin on the new filter canister by hand until the
gasket just touches the mounting pad and then

turn it an additional 1/2 to 3/4 turn. Do not over­tighten.

8. Refill with API Class SG or SH oil (also SG/CD,
SG/CE, SH/CD or SH/CE) having an SAE vis-
cosity grade appropriate for the expected tem-

peratures, as indicated by Table 1. See Speci-
fications for the oil capacity.

DO NOT FILL TO A LEVEL ABOVE THE FULL
MARK ON THE DIPSTICK. Drain the excess
oil if too much has been added.

+*54/10

Too much oil can cause high oil
consumption, high operating temperatures
and oil foaming. Too little oil can cause se-

vere engine damage. Keep the oil level be-
tween the Full and Add marks on the dip-
stick.

9. Reconnect the spark plug and battery.

10.Start the engine and run it for a short time while
checking for oil leaks around the drain plug and
oil filter. Do not overtighten: tighten only as nec­essary to eliminate leaks.

11.Used oil is harmful to the environment. Pour
the used oil into a sealed container and deliver
it to the nearest recycling center.

10

AIR CLEANER MAINTENANCE

Refer to Table 2 for scheduled foam wrapper main-
tenance and air cleaner element replacement. See
Figure 5.

Outer Cover

To remove the outer cover, rotate the quarter-turn
fastener counterclockwise to its vertical position.
Then lift the cover and remove it. To reinstall the out­er cover, place the cover over the base, push the
quarter-turn fastener in and then rotate it clockwise
to its horizontal position.

Foam Wrapper Maintenance

When performing maintenance on the foam wrap­per only, do not remove the inner air cleaner cover.
Remove and wash the foam wrapper in water and
detergent. Squeeze the foam wrapper dry like a

sponge. Rinse with clean water and allow it to dry.
Coat the wrapper evenly with one tablespoon

(14 grams) of SAE 30 engine oil. Knead the oil into
the wrapper and wring out the excess oil.

Failure to adequately wring out excess oil from the
wrapper may cause a drop in engine power due to a
restriction of inlet air.

Install the foam wrapper over the paper air cleaner
element by stretching it over the inner cover. Com­pletely cover all exposed paper pleats. Replace the
foam wrapper when it becomes torn or stretched.

Air Cleaner Element Replacement

To keep anything from entering the carburetor and
engine while the air cleaner element is off, pull the

choke knob to the full-choke position to close the
choke plate in the carburetor. Remove the outer
cover and wipe away loose dust and debris from the
air cleaner assembly. Remove the mounting nut, in-
ner cover and air cleaner element. Wipe off dust
and debris from the air cleaner base.

Install the new paper element and secure it with the

inner cover and mounting nut. Tighten the nut 1-1/2
turns after seating it on the cover. Reinstall the foam
wrapper and outer cover.

QUARTER-TURN

FASTENER

OUTER
COVER

MOUNTING

NUT

/9&$%$

INNER

COVER

FIGURE 5. AIR CLEANER ASSEMBLY

FOAM

WRAPPER

SEAL

AIR CLEANER

ELEMENT

AIR CLEANER

ASSEMBLY BASE

11

COOLING SYSTEM MAINTENANCE

Refer to Table 2 for scheduled cleaning of the cylin-
der cooling fins.

Use compressed air or a pressure washer to clean
the cylinder cooling fins. Ta ke the following precau-
tions.

1. Wear safety glasses.

6*20/0-

Always wear safety glasses
when using compressed air or a pressure
washer to avoid severe eye damage.

2.Let the engine cool, especially when using a
pressure washer. The temperature stresses

caused by cleaning a hot engine can crack the
cylinder.

3.Observe all of the manufacturer’s instructions
and precautions when using a pressure
washer.

FUEL FILTER REPLACEMENT

Refer to Table 2 for scheduled fuel filter replace-
ment and Figure 3 for the location of the fuel filter (if

so equipped). Also refer to the equipment Opera-
tor’s Manual regarding any supplemental fuel filters
that may have been provided and the recom-

mended frequency for their replacement.
Take care not to spill fuel when disconnecting the

fuel line from the filter. Allow the engine to cool be-

fore disconnecting the fuel line so that it cannot ig­nite any fuel that may be spilled. Close any shutoff
valve that may be provided in the fuel line. If the filter
is of the in-line type, it is usually removable by loos­ening the inlet and outlet hose clamps.

6*20/0-

Gasoline is highly flammable and

can cause severe personal injury or death.
Let the engine cool and close any fuel line shut-

off valve before disconnecting the fuel line from
the filter.

Do not smoke if you smell gasoline or are near
fuel tanks or gasoline-burning equipment or are
in an area sharing ventilation with such equip-
ment. Keep flames, sparks, pilot lights, electri­cal arcs and arc-producing equipment and all
other sources of ignition well away.

SPARK PLUG MAINTENANCE AND

REPLACEMENT

Refer to Table 2 for scheduled spark plug inspection
and replacement and to Specifications for gap
specifications.

To prevent crossthreading the spark plug always
thread it in by hand until it seats. If the spark plug is
being reused, turn it with a wrench an additional 1/4

turn. If the spark plug is new, turn it an additional 3/8
to 1/2 turn. If you have a torque wrench, tighten the
spark plug to 20 lbs-ft (26 N-m).

12

CHOKE CABLE

SLACK OUT

THIS WAY

THROTTLE CABLE

FULL-OPEN

CHOKE

POSITION

ALTERNATE

CABLE CLAMP

LOCATIONS

CHOKE CABLE

(above throttle

cable)

CHOKE

CONTROL ARM

(above throttle

control arm)

THROTTLE

CONTROL ARM

(below choke

control arm)

ALTERNATE

CABLE CLAMP

LOCATIONS

SLACK OUT

THIS WAY

THROTTLE

SHAFT ARM

AND STOP

SCREW

(LOW-IDLE)

THROTTLE

CABLE

(below choke

cable)

STOP PLATE

(HIGH-IDLE)

Adjustments

These engines have precision-manufactured car-
buretors which are not adjustable.

RECONNECTING AND RECLAMPING THE

If the engine is so equipped, the choke and throttle
cables are secured (choke cable above throttle
cable) by a single clamp to a bracket at the top of the
engine (Figure 6). If necessary, reconnect and re-
clamp the cables as follows:

1. Stop the engine and disconnect the spark plug

CARBURETOR ADJUSTMENTS

CHOKE AND THROTTLE CABLES

and, if so equipped, the battery (negative [–]
cable).

6*20/0-

gine can result in severe personal injury or
death. Always disconnect the spark plug

and battery (negative [–] cable) before re-
setting the engine control cables.

Accidental starting of the en-

2.Push the choke knob in to the full open-choke

position and the equipment throttle lever to its
lowest speed position.

3.Loosen the cable clamp at the engine bracket if

necessary and hook the cable wires into the
hook holes in the choke and throttle control

arms, if not already hooked. Note that there are
two hook holes in each control arm. Make sure
the wires are hooked appropriately, as shown,
for the cable clamp location being used. Other-
wise, the cable will bind, preventing full move-

ment.

4. Rotate the choke and throttle control arms

clockwise, and while holding them against their
stops, pull the slack out of the cables and tight-

en the cable clamp.

5. Check for smooth movement and full travel of

the equipment choke knob and throttle lever.
Remove the air cleaner element as instructed
under Periodic Maintenance to see that the
choke plate opens and closes fully. Move the
equipment throttle lever to see that the throttle
control arm touches the stop plate and that the

throttle shaft arm touches the stop screw.

6.Reassemble the air cleaner and reconnect the

spark plug and battery.

13

FIGURE 6. CHOKE AND THROTTLE CABLES

ENGINE SPEED ADJUSTMENTS

Normally there is no need to adjust engine speed.
These instructions are for the equipment manufac-
turer in setting up and adjusting the equipment.

Service personnel should note that following reas-

sembly of either the carburetor or intake manifold to
the engine, it is necessary to reposition the gover-

nor arm (Figure 3) on the governor shaft BEFORE
making speed adjustments so as to compensate for
the slightly different alignment of parts. See the en­gine Service Manual.

Engine speed adjustment must be attempted only
by a qualified mechanic and the adjustments must
be made using an accurate tachometer. Set the

low-idle and high-idle speeds to the values speci­fied in the equipment Operator’s Manual. In the ab-
sence of such specifications it is recommended that
low-idle speed be adjusted to 1400 RPM and high-
idle speed to 3400 RPM.

6*20/0-

ue above that specified by the equipment
manufacture could cause the equipment to op-
erate at speeds in violation of Federal and State
Standards for Safety for the equipment.

6*20/0-

sonal injury or death. Take care when measur-

Adjusting the engine speed to a val-

Moving parts can cause severe per-

ing engine speed with a tachometer and follow
the meter instructions. You must be a qualified

mechanic.

Referring to Figure 7, adjust the low-idle and high-
idle engine speeds as follows:

1. If necessary, reconnect and reclamp the choke

and throttle cables as instructed in this section.

2.Start the engine, observing all of the equipment

manufacturer’s instructions and precautions,
and move the equipment (engine) throttle lever

to its lowest speed position.

3.Adjust the low-idle speed stop screw (on the
carburetor) to obtain the specified low-idle
speed.

4. On cable controlled engines move the equip-
ment throttle lever to its highest speed position.
Loosen the high-idle speed stop plate clamp­ing screw and rotate the stop plate while hold-
ing the throttle control arm against it until the

specified high-idle speed is obtained and then
retighten the clamping screw. On lever con-
trolled engines adjust the lever stop screw
while holding the throttle lever up against it until
the specified high-idle speed is obtained.

5. Check for full, smooth movement of the throttle
control arm (lever) between its two stop posi-

tions.

CABLE CONTROLLED ENGINES LEVER CONTROLLED ENGINES

HIGH-IDLE

SPEED STOP

PLATE

THROTTLE

CONTROL ARM

(below choke

control arm)

LOW-IDLE SPEED

STOP SCREW

(on the carburetor)

Note: Do not loosen the high-idle speed stop plate (stop screw) unless you are a qualified mechanic and have an
accurate tachometer to set the high-idle speed in accordance with the equipment manufacturer’s specifications.

FIGURE 7. SPEED ADJUSTMENTS

THROTTLE LEVER

(full open position)

CHOKE LEVER

(full open position)

HIGH-IDLE SPEED

STOP SCREW

14

EXHAUST OUTLET ADJUSTMENT

The muffler (when the engine is so equipped) has
an outlet nozzle that can be rotated in increments of

30 degrees to point in a direction better suited for
the application. To reorient the nozzle, remove the

four mounting nuts and reattach the nozzle to point
in the desired direction. See Figure 8.

EXHAUST OUTLET NOZZLE

6*20/0-

EXHAUST GASES ARE DEADLY!
Orient the exhaust outlet nozzle away from the
equipment operator.

Exhaust gases are hot and can melt fuel tanks

or cause the fuel to boil, leading to severe injury
or death. Orient the exhaust outlet nozzle away
from fuel tanks.

RECOIL STARTER HANDLE

ADJUSTMENT

The recoil starter handle (when the engine is so
equipped) can be relocated in increments of 30 de­grees around the crankshaft center line. To relocate
the handle, remove the four recoil starter assembly
mounting nuts and reattach the assembly so that

the handle is more conveniently located. See Fig-
ure 9.

FIGURE 8. EXHAUST OUTLET NOZZLE

RECOIL STARTER HANDLE

15

FIGURE 9. RECOIL STARTER HANDLE

Troubleshooting

Table 3 provides basic troubleshooting guidance. If
you fail to resolve the problem after taking the cor-
rective actions suggested, contact the equipment
or Onan dealer.

6*20/0-

present hazards that can result in severe per-
sonal injury or death. Only qualified service per-

Many troubleshooting procedures

TABLE 3. TROUBLESHOOTING

Problem Corrective Action

1. The engine fails to crank (elec­tric start engines).

2.The engine cranks slowly (elec-
tric start), or the recoil starter is

hard to pull.

a.Release the clutch (if so equipped).
b.Clean and tighten the positive ( + ) and negative ( – ) battery

cable connections at the battery and the engine.

c.Recharge the battery. Refer to the equipment or battery

manufacturer’s recommendations.

a.Release the clutch (if so equipped).
b.If electric start, clean and tighten the positive ( + ) and nega-

tive ( – ) battery cable connections at the battery and the en-
gine.

c.If electric start, recharge the battery. Refer to the equip-

ment or battery manufacturer’s recommendations.

d. Change engine oil to oil having the proper viscosity for the

ambient temperature. See Table 1.

sonnel with knowledge of fuels, electricity, and
machinery hazards should perform service pro-
cedures. Review the safety precautions on the
inside cover page.

6*20/0-

burns. Always allow the engine time to cool
before performing any maintenance or service.

Hot engine parts can cause severe

3.The engine cranks but fails to
start.

4. The engine runs and then stops. a.Check the fuel tank and fill if necessary.

5. The engine exhausts black
smoke.

a.Check the fuel tank and fill if necessary.
b.Open any closed fuel shut off valve.
c.Check engine oil level and add oil as necessary.

d. Reconnect and reclamp the choke and throttle cables, if

necessary. See Adjustments.

e. Service the air cleaner.

f. Replace the fuel filter(if provided).

g. Inspect and clean or replace the spark plug and re-gap it.

b.Check the engine oil level and add oil as necessary. Drain

excess oil if the level is above the dipstick Full mark.

c.Reconnect and reclamp the choke and throttle cables, if

necessary. See Adjustments.

a.Service the air cleaner.
b.Reconnect and reclamp the choke and throttle cables, if

necessary. See Adjustments.

16

Specifications

MODEL E125H MODEL E140H

Engine Type

Bore 3.31 inches (84.2 mm) 3.31 inches (84.2 mm)

Stroke 2.76 inches (70.0 mm) 2.76 inches (70.0 mm)

Displacement 23.7 inches3(390 cc) 23.7 inches3(390 cc)

Compression Ratio 8.5 : 1 8.5 : 1

Power at Rated Speed (3600 RPM) 12.5 HP (9.3 kW) 14.0 HP (10.4 kW)

Oil Capacity (with Filter)* 1 quart (0.95 l) 1 quart (0.95 l)

Intake Valve Clearance (Cold) 0.006 inches (0.15 mm) 0.006 inches (0.15 mm)

Exhaust Valve Clearance (Cold) 0.006 inches (0.15 mm) 0.006 inches (0.15 mm)

Spark Plug Gap 0.035 inches (0.89 mm) 0.035 inches (0.89 mm)

Spark Plug Tightening Torque 20 lbs-ft (26 N-m) 20 lbs-ft (26 N-m)

Ignition Timing (Non-adjustable, elec-

tronic, magneto ignition)

1-Cylinder, 4-Stroke Cycle, Spark-Ignited, OHV, Air-Cooled,

Horizontal-Shaft

23° BTDC 23° BTDC

* –See Periodic Maintenance for oil filling instructions.

17

Important Information

for California Engine Users

These engines meet the requirements of Califor-
nia’s Exhaust Emissions Standards for 1995 and
later for Utility and Lawn and Garden Equipment

Engines.

As a California user of these engines, please be
aware that unauthorized modifications or replace-

ment of fuel, exhaust, air intake, or speed control
system components that affect engine emissions

are prohibited. Unauthorized modification, removal
or replacement of the engine label is prohibited.

TABLE 4. EMISSIONS CONTROL INFORMATION

The California emissions control warranty statement is located

Engine Warranty Information

Engine Valve Lash See Specifications.

Engine Ignition Timing See Specifications.

Engine Fuel Requirements

in the same packet of information as this manual when the en-
gine is shipped from the factory.

The engine is certified to operate on unleaded gasoline. See
Fuel Recommendations in Introduction.

You should carefully review Operator (Owner),
Installation and other manuals and information you

receive with your engine or equipment. If you are
unsure that the installation, use, maintenance or
service of your engine or equipment is authorized,
you should seek assistance from an approved

Onan engine dealer or an approved dealer for your
equipment.

California engine users may use Ta ble 4 as an aid in
locating information related to the California Air Re-

sources Board requirements for emissions control.

Engine Lubricating Oil Requirements See Engine Oil Recommendations in Introduction.

Engine Fuel Mixture Settings

Engine Adjustments See Adjustments.

Engine Emission Control System

These engines have precision-manufactured carburetors
which are not adjustable.

The engine emission control system consists of internal engine
modifications.

18

Cummins Power Generation
1400 73rd Avenue N.E.

Minneapolis, MN 55432
763-574-5000

Fax: [phone]

Cummins and Onan are registered trademarks of Cummins Inc.